TECHNICAL INSTRUCTIONS #11 REGULATOR 3-Way Water Mix (Type WM)

The Powers #11 Water Mix Regulator is a self-actuating control valve which

auto-matically maintains a mixture of hot and cold water at the desired set point without

the use of external power. Adjust the set point and the rugged self-operating #11

Regulator controls the mix of hot or cold water to maintain a constant temperature.

The instrument has a vapor pressure thermal system containing a thermally

respon-sive fluid. This thermal system rapidly senses temperature changes at the bulb and

accordingly positions the valve disc or plug, regulating hot and cold water flow to

maintain the desired set point. The thermal system features a two-ply brass bellows

with six reinforcing ribs on the bellows head and thick capillary tubing walls to insure

long operating life.

The Powers #11 WM Regulator features:

• Tight disc shutoff when either of the two inlet ports are closed (up to 2")

• EPT disc is replaceable (on 1/2"-2" valves).

• Lower guide stabilizes valve plug, assisting shutoff and modulation.

• EPT spring loaded V-ring packing provides good sealing and long life.

• A valve stem of highly polished corrosion resistant grade 316L stainless steel to

decrease friction and reduce hysteresis.

• An adjusting nut mounted on ball bearings and a removable set point adjusting

rod ease set point adjustments

• A set point reference scale aids temperature adjustment.

The #11 Regulator should be installed with

the hotter of the two liquids going into the

bottom ‘B’ port and the cooler liquid going

into the upper ‘U’ port.

(A) When the temperature of the mixed liquid

drops below the set point, the temperature of

the thermally responsive fluid decreases,

which decreases the vapor pressure in the

bulb/bellows. The force of the resulting vapor

pressure is less than the spring force, so the

bellows contract and the spring extends,

which raises the valve plug up to decrease

flow through the upper ‘U’ port (cold) and

increase flow through the bottom ‘B’ port

(hot). This raises the temperature of the flow

out of the common ‘C’ port toward the set

point.

(B) As the temperature increases toward or

beyond the desired set point, the

tempera-ture of the thermally responsive fluid in the

bulb increases, which causes the vapor

pres-sure to increase. This expands the bellows,

compresses the spring, and moves the valve

plug down to increase flow through the upper

‘U’ port (cold) and decrease flow through the

Temp. Below Set Point Temp. Above Set Point U C B U C B VAPOR LIQUID BULB CAPILLARY TUBING SPRING BELLOWS VALVE PLUG LIQUID VALVE PLUG SEATS VALVE PLUG VALVE PLUG SEATS Cold Mixed Hot Cold Mixed Hot

Valve Description ...1

Operation ...1

Applications ...2

Specifications...3

Sizing and Selection ...3

Maximum Water Capacities ...4

Product Identification ...5

Installation ...5

Maintenance ...6

Preventive Maintenance ...9

Troubleshooting ...9

Dimensions...10

Parts List ...12

Accessories ...14

Temp. Ranges/Bulb Sizes ...14

Ordering Code ...15

Warranty Information ...16

(B)

(A)

VALVE DESCRIPTION

TABLE OF CONTENT

OPERATION

TECHNICAL INSTRUCTIONS

#11 REGULATOR 3-Way Water Mix (Type WM)

IS-P-595WM

U = Upper Port/Cold Water Inlet B = Bottom Port/Hot Water Inlet C = Combination Port/Mixed Water Outlet

TWO TEMPERATURE HOT WATER SYSTM

JACKET WATER COOLING APPLCIATION

Powers #11 Water Mix Regulators are typically used for automatic control of domestic or process water tempering. The self-actuated regulator can easily be installed in any convenient location. Among its applications are: two-temperature hot water systems, jacket water cooling of engines or compressors, and many other industri-al processes. Below are two typicindustri-al applications.

The three-way regulator can also be used for bypass control, in lieu of a diverting valve, but it must be piped as a mixing valve, with two inlets and one outlet.

WARNING:

In domestic water system, a safety shutdown

device should be installed in conjunction with a #11

regulator. Failure of the #11 thermal system will

result in a constant rise in temperature (or constant

high temperature ) of the fluid which you are trying

to control.

APPLICATIONS

Pump Cool Water from_{Heat Exchanger}

Hot Water to Heat Exchanger Bulb in Well By-Pass #11 Regulator DS Double Seat DIRECT ACTING #11 Regulator WM Water Mix Bulb in Well Bulb in Well Steam Supply Pump Pump Check Valves

Cold Water Supply

HTHW Return WATER HEATER Tempered Return HTHW Tempered Water To Condensate Return

ment AE-1—“Valve Selection and Sizing”—for further recommen-dations.

Maximum Operating Pressure Differential (differential for fluid flow): In order for the process medium to flow, a pressure drop

must exist across the valve. “Pressure differential” is the difference in valve pressure between the inlet and outlet under flow condi-tions. The greater the differential, the greater the flow at any given plug position.

Though the regulator should be sized for actual conditions, you need to know the available differential at maximum flow. For opti-mum control, take as much differential as possible across the valve.

Refer to Maximum Water Capacities tables on page 4.

PRODUCT IDENTIFICATION

SIZING AND SELECTION

Proper sizing of the Regulator is essential for correct system oper-ation. An undersized Regulator will not allow sufficient flow at max-imum load. An oversized Regulator may cycle and will not utilize the full valve stroke for efficient modulation of flow. This results in poor control and shortened valve life (quicker deterioration of valve disc and seat). For these reasons, the correct sizing of the Regulator for actual expected conditions is considered essential for good control.

Note: Select temperature range (see page 14) with the set point in the upper third for best valve performance.

Size the #11 Regulator for actual rather than maximum conditions. DO NOT size according to pipe size; piping systems are designed for different criteria than process controls. Refer to Powers

docu-SPECIFICATIONS

Valve Sizes

1/2", 3/4", 1", 1-1/4", 1-1/2", 2" 2-1/2", 3", 4"

Valve Plug Travel See table on page 10 See table on page 10

Effective Bellows Area 7.8 sq. in. (50.3 sq. cm.) 7.8 sq. in. (50.3 sq. cm.)

Body Material Bronze Cast Iron

Body Rating ANSI Class 125 ANSI Class 125

Connections Screwed Ends Flanged Ends

Style Composition Disc Bronze Trim

Max. Body Temperature 400°F (204°C) 350 °F (177°C)

Temperature Range See bulb spec on page 13 See bulb spec on page 13

Controlled Medium Water Water

Max. Differential Pressure See Tables on pp. 3 & 4 See Tables on pp. 3 & 4

Max. Allowable Overheat Temp. 25°F (14°C) above temp. range 25°F (14°C) above temp. range

Max. Well Safe Pressure See Tables on page 11 See Tables on page 11

Max. Body Pressure 125 psig 125 psig

Shipping Weight See Table on page 10 See Table on page 10

Flow Characteristics Linear Linear

Shutoff Class Rating ANSI Class IV ANSI Class III

CAUTION: Do not exceed maximum pressure differentials for given valve sizes. The maximum differential is the

pressure the valve has against it at shutoff. Too large a differential can cause valve chatter and/or prevent shutoff.

MAXIMUM WATER CAPACITIES

TEMPERING Applications - Maximum MIXED FLOW

Gallons Per Minute Liters per Second

Valve Available Sizing Pressure Differential --- PSI Valve Available Sizing Pressure Differential --- kPa

Size Cv 2 4 6 8 10 15 20 25 30 40 50 Size 7 15 30 45 60 75 100 125 150 200 250 350 1/2" 4.2 5.9 8.4 10 12 13 16 19 21 23 27 30 1/2" 0.3 0.4 0.6 0.7 0.8 0.9 1 1.1 1.2 1.4 1.6 1.9 3/4" 7.2 10 14 18 20 23 28 32 36 39 46 51 3/4" 0.5 0.7 0.9 1.2 1.3 1.5 1.7 1.9 2.1 2.4 2.7 3.2 1" 12 17 24 29 34 38 46 54 60 66 76 85 1" 0.8 1.1 1.6 1.9 2.2 2.5 2.9 3.2 3.5 4.1 4.6 5.4 1-1/4" 20 28 40 49 57 63 77 89 100 110 126 141 1-1/4" 1.3 1.9 2.6 3.2 3.7 4.2 4.8 5.4 5.9 6.8 7.6 9 1-1/2" 25 35 50 61 71 79 97 112 125 137 158 177 1-1/2" 1.6 2.3 3.3 4 4.7 5.2 6 6.7 7.4 8.5 9.5 11 2" 39 55 78 96 110 123 151 174 195 214 247 276 2" 2.5 3.6 5.1 6.3 7.3 8.1 9.4 10 11 13 15 18 2-1/2" 77 109 154 189 218 243 298 344 385 422 – – 2-1/2" 4.9 7.2 10 12 14 16 18 21 23 26 – – 3" 120 170 240 294 339 379 465 537 600 657 – – 3" 7.6 11 16 19 22 25 29 32 35 41 – – 4" 145 205 290 355 410 459 562 648 725 794 – – 4" 9.2 13 19 23 27 30 35 39 43 49 – –

BYPASS Applications - FULL FLOW thru BOTTOM Port (Top Closed)

Gallons Per Minute Liters per Second

Valve Available Sizing Pressure Differential --- PSI Valve Available Sizing Pressure Differential --- kPa

Size Cv 2 4 6 8 10 15 20 25 30 40 50 Size 7 15 30 45 60 75 100 125 150 200 250 350 1/2" 2.2 3.1 4.4 5.4 6.2 7 8.5 9.8 11 12 14 16 1/2" 0.1 0.2 0.3 0.4 0.4 0.5 0.5 0.6 0.6 0.7 0.8 1 3/4" 6 8.5 12 15 17 19 23 27 30 33 38 42 3/4" 0.4 0.6 0.8 1 1.1 1.2 1.4 1.6 1.8 2 2.3 2.7 1" 8.9 13 18 22 25 28 34 40 45 49 56 63 1" 0.6 0.8 1.2 1.4 1.7 1.9 2.1 2.4 2.6 3 3.4 4 1-1/4" 16 23 32 39 45 51 62 72 80 88 101 113 1-1/4" 1 1.5 2.1 2.6 3 3.3 3.8 4.3 4.7 5.4 6.1 7.2 1-1/2" 18 25 36 44 51 57 70 80 90 99 114 127 1-1/2" 1.1 1.7 2.4 2.9 3.3 3.7 4.3 4.8 5.3 6.1 6.8 8.1 2" 30 42 60 73 85 95 116 134 150 164 190 212 2" 1.9 2.8 3.9 4.8 5.6 6.2 7.2 8.1 8.8 10 11 13 2-1/2" 77 109 154 189 218 243 298 344 385 422 – – 2-1/2" 4.9 7.2 10 12 14 16 18 21 23 26 – – 3" 120 170 240 294 339 379 465 537 600 657 – – 3" 7.6 11 16 19 22 25 29 32 35 41 – – 4" 145 205 290 355 410 459 562 648 725 794 – – 4" 9.2 13 19 23 27 30 35 39 43 49 – –

BYPASS Applications - FULL FLOW thru UPPER Port (Bottom Closed)

Gallons Per Minute Liters per Second

Valve Available Sizing Pressure Differential --- PSI Valve Available Sizing Pressure Differential --- kPa

Size Cv 2 4 6 8 10 15 20 25 30 40 50 Size 7 15 30 45 60 75 100 125 150 200 250 350 1/2" 3.5 4.9 7 8.6 9.9 11 14 16 18 19 22 25 1/2" 0.2 0.3 0.5 0.6 0.7 0.7 0.8 0.9 1 1.2 1.3 1.6 3/4" 6 8.5 12 15 17 19 23 27 30 33 38 42 3/4" 0.4 0.6 0.8 1 1.1 1.2 1.4 1.6 1.8 2 2.3 2.7 1" 11 16 22 27 31 35 43 49 55 60 70 78 1" 0.7 1 1.4 1.8 2 2.3 2.6 3 3.2 3.7 4.2 4.9 1-1/4" 17 24 34 42 48 54 66 76 85 93 108 120 1-1/4" 1.1 1.6 2.2 2.7 3.2 3.5 4.1 4.6 5 5.8 6.5 7.6 1-1/2" 24 34 48 59 68 76 93 107 120 131 152 170 1-1/2" 1.5 2.2 3.2 3.9 4.5 5 5.8 6.4 7.1 8.2 9.1 11 2" 38 54 76 93 107 120 147 170 190 208 240 269 2" 2.4 3.5 5 6.1 7.1 7.9 9.1 10 11 13 14 17 2-1/2" 77 109 154 189 218 243 298 344 385 422 – – 2-1/2" 4.9 7.2 10 12 14 16 18 21 23 26 – – 3" 120 170 240 294 339 379 465 537 600 657 – – 3" 7.6 11 16 19 22 25 29 32 35 41 – – 4" 145 205 290 355 410 459 562 648 725 794 – – 4" 9.2 13 19 23 27 30 35 39 43 49 – –

PRODUCT IDENTIFICATION

A red label should be on the front face of the thermal system. Figure 1. This label contains information required to properly

main-tain, service and order parts for this product. If there is no label, look for a white label on the inside of the thermal system legs (Figure 2A) or the valve body vertical yoke (Figure 2B). When replacing the original thermal assembly or valve body, secure the old red label onto the valve or thermal system or ink the number onto the body.

INSTALLATION

TOOLS NEEDED

• Straight slot screwdriver • 5/16" open end wrench • 3/8" open end wrench • 7/16" open end wrench • 1-3/8" open end wrench • Pliers

• 1/2" wrench for hi-power regulator housing bolts BEFORE INSTALLING VALVE

1. Figure 3. For 2-1/2” to 4” valves, remove bellows stops before installation and use.

2. To insure proper system operation, thoroughly flush all piping and valves to rid them of all scale, dirt and debris.

Position Valve

3. Select valve location with sufficient clearance to allow mainte-nance. Install valve in line. The direction of the arrows on the valve body must match the direction of the water or steam flow.

For best results, we recommend installing the valve in a hori-zontal line, and in the upright position with bellows head above valve. The valve may also be installed in any position within 90° of upright.

4. Figure 4. The direction of the arrows on the valve body must match the direction of the water flow.

Pipe the hot water to the bottom ‘B’ port, and the cold water to the upper ‘U’ port. The mixed water will exit the valve through the common ‘C’ port.

DO NOT reverse the inlets; the valve will not properly control the temperature of the mixed water if hot and cold supplies are reversed.

INSTALL BULB

5. Figure 5a shows proper bulb orientation. Figure 5b shows the special bulb needed for upwards vertical positioning. 6. Figure 6. For any position, fully immerse the bulb in the flow of

the medium.

These instructions are for D style bulbs - for installation of other styles, refer to tag attached to bulb.

Correct: Bulb in flow of medium Incorrect: Bulb not in flow of medium

U C

B _{Hot Water Inlet}

Tempered Water Outlet Cold Water Inlet

1. PRODUCT LABEL

2B. VALVE BODY LABEL 2A. THERMAL SYSTEM LABEL

3. BELLOWS STOPS Bellows Stop Bellows Stop Removed 4. INLET PIPING

WORD "TOP" ON FLAT SURFACE FACING UP

HEAD END

TOP Standard Bulb

Downward Vertical (left) or Horizontal (below) Only Special Bulb Upward Vertical Only (right) 5B. SPECIAL BULB 5A. BULB ORIENTATION

4. Figure 8. Remove housing bolts [6] and nuts [7] and tempera-ture adjustment setting scale [8] and lift off thermal system [1] (housing, bellows, capillary, and bulb).

5. Figure 9A. For the 1/2" to 2" valves, use one 3/8" wrench and one 5/16" wrench, carefully loosen and remove piston plate assembly [2,3] from the stem extension [4].

Lift off spring [19].

Figure 9B. For the 2-1/2" to 4" valves, use two 3/8" wrench-es to carefully loosen piston plate/shank [3] from the stem extension [4]. Make sure the spring is fully decompressed, slowly remove piston plate assembly. Lift off the spring seat and the spring.

7. Without a well: Remove bushing from the bulb and screw it

into the tank. Insert the thermostatic bulb through the bushing and tighten the union nut.

With a well: Do not use bushing. Screw well into tank, insert

bulb directly into well, and tighten union nut.

ADJUST CAPILLARY TUBING

8. Coil the extra capillary, and position away from regulator oper-ation where it is subjected to room temperature only.

ADJUST SET POINT

All regulators are factory set to control near mid-range operating temperature.

9. When adjusting the set point, make certain all fluids are flow-ing through the

valve and are at the operating pressure of the system. 10. Figure 7. Make all set

point temperature changes by insert-ing the temperature adjustment rod into one of the holes of the adjusting nut assembly. (Use the temperature adjust-ment setting scale only for reference)

To Raise the set point: Turn rod left

to right (counter-clockwise from top).

To Lower the set point: Turn rod right

to left (clockwise from top).

MAINTENANCE

Numbers in brackets [#] refer to part numbers on pp. 12 & 13. To fully disassemble regulator from valve

1. Figure 3. For 2-1/2” to 4” valves, replace bellows stops before performing any service or maintenance.

2. Before disassembly, the bulb must be cooled 30°F (16°C) below the lowest point on the thermal system range, and flow through the valve must be stopped.

3. Figure 7. Relieve all pressure on the spring by turning adjust-ing nut assembly [31] fully right to left (clockwise from top).

WARNING: DO NOT kink, cut, sever or file the tubing.

DO NOT disconnect tubing from bulb or bellows

assembly. This can render the thermal system

inopera-ble and result in severe process overheating.

7. ADJUSTING SET POINT

8. REMOVE HOUSING AND THERMAL SYSTEM

3/8" Nut

5/16" Nut Piston Plate

Assembly

Spring

9A. (1/2" TO 2") REMOVE PISTON PLATE AND SPRING

9B. (2-1/2" TO 4") REMOVE PISTON PLATE/SHANK AND SPRING Piston Plate/ Spring Seat 3/8" Shank 3/8" Stem Extension Spring

7. Figure 12A. For 1/2" to 2" valves: Unscrew and remove valve seat [25]. Pull down valve plug assembly [23 & 24]. Remove disc lock nut, both disks and other parts [23a-e]. Replace with new discs and reassemble.

Figure 12B. For 2-1/2 to 4" valves: Remove four flange cap screws [28]. Remove valve flange and seat assembly [27]. Pull down plug assembly [24], unscrew stem head retainer [22] and replace valve plug. Replace gasket [21] Assemble in reverse order.

6. Use a 1-3/8" wrench to unscrew lock nut [11].

Figure 10A. For the 1/2" to 2" valves, the bridge and yoke are a one-piece assembly [9]. Lift them off.

Figure 10B. For the 2-1/2 to 4" valves, the cast iron bridge and yoke can be separated. Lift both off.

To replace valve plug, disks and gaskets

Follow steps 1-5, To fully disassemble regulator from valve. 6. Figure 11. For all WM valve sizes, use the 3/8" wrench on the

stem extension [4] and the 7/16" wrench on the hex nut [12] to loosen and remove them.

Locknut

10A. (1/2" TO 2") LIFT OFF BRIDGE/YOKE ASSEMBLY Yoke and

Bridge

Bridge

Yoke

Locknut

10B. (2-1/2" TO 4") LIFT OFF BRIDGE AND YOKE

Stem Assembly 7/16" Hex Nut 5/16" Stem

Extension

11. REMOVE STEM EXTENSION AND HEX NUT

Valve Seat Disc Assembly

Stem Body

12A. (1/2" TO 2") PLUG ASSEMBLY

12B. (2-1/2" TO 4") PLUG ASSEMBLY Flange/Seat Plug Assembly Stem Stem Head Retainer Gasket

17. With stem in full UP position (the valve plug firmly seated), screw stem extension [4] to the dimension shown in Figure 14 and tighten into place with hex nut [12].

18. Make sure the valve stem is in the full up position when replac-ing the sprreplac-ing seat and piston plate assembly on the large valves.

19. Assemble the remaining parts in reverse order.

TESTING THE THERMAL SYSTEM

1. Stop the flow of fluid through the line.

2. Raise the temperature of the bulb above the set point temper-ature by placing it in a container of hot water. This will cause the plug to fully seat.

3. Figure 15. With the valve plug seated in the bottom port "B," use a felt tip pen to mark the position of the packing gland assembly on the stem.

4. Place the bulb in a pan of cool water. Cool the bulb 30°F (16°C) below set point so the valve is fully open.

5. With the valve plug now seated on the upper port “U,” use the pen to mark the new position of the packing gland assembly on the stem.

To replace packing

Follow To fully disassemble regulator from valve steps 1-6. 6. Figure 11. Use a 5/16" wrench on the flats of the stem

exten-sion [4] and a 7/16" wrench on the hex nut [12] to loosen and remove them.

7. Use the 1-3/8" wrench to loosen and remove bonnet [20]. 8. Carefully pull out stem assembly [30]. Check the stem. It must

have a polished surface that is free of roughness and pitting. Replace any parts if necessary.

9. Figure 13. Remove packing gland [14], and all packing com-ponents [15a-15e].

10. Clean packing chamber, taking care not to scratch seating surfaces. Be sure chamber is free of dirt and grease. 11. For 1" - 2" valves, place the upper gasket [21] on body before

the bonnet.

12. Replace bonnet [20] and stem [30] into valve body.

NOTE: You must replace the bonnet and stem before

attempt-ing to insert the packattempt-ing. Otherwise, you may tear the packattempt-ing rings.

13. For standard packing kits, install the parts as shown in Figure 13.

Slide part(s) [15e], followed by [15d] and [15c] over the stem. Gently push them into the packing chamber.

NOTE: Some kits do not include all the listed packing parts (see page 12), but the order for part installation is the same. 14. For EP V-rings, lubricate the rings first.

Slide each V-ring [15b] over the stem and carefully push it into the packing chamber.

15. Place the packing gland spacer [15a] on top of the bonnet. 16. Thread the packing gland assembly [14] into the bonnet.

Tighten the gland assembly against the spacer.

Stem Setting Dimension (See Above) Valve Size 1/2" to 2" 2-1/2" to 4" 10-1/16" (+1/32, -0) 8-3/16" (+1/32, -0) [256mm (+.79, -0)] [208mm (+.79, -0)] 13. PACKING COMPONENTS Packing Kit

(15a-e) Packing Gland Spacer Packing Gland Bonnet Hex Nut Top of Stem Extension Top of Bonnet

SEE CHART BELOW

14. STEM EXTENSION REASSEMBLY DIMENSION

Distance between two marks = Valve

Travel

• Temperature of discharge water too low

1. Temperature adjusting nut assembly set too low. Refer to

Adjust Set Point.

2. A radical drop in the hot water supply temperature or pres-sure. Check supply waters.

3. Valve cannot close against cold inlet. Foreign material may be caught between the disc and the valve plug seat. Refer to

Replacing the composition disc for disassembly. Clean. • Temperature of discharge water too high

1. Temperature adjusting nut assembly set too high. Refer to

Adjusting Set Point.

2. Thermal system failure. Refer to Testing the Thermal

System.

3. Incorrect piping to valve. Refer to Operation and/or

Installation.

4. Bulb is poorly positioned and/or oriented, and will not control the actual temperature of the heating/cooling medium. Refer to Install Bulb.

5. Incorrect type of bulb is being used. See Table on page 11. 6. Pressure differential is greater than allowable pressure drop.

Refer to Water Mixing Capacities tables.

7. Disc is worn. Replace disc (refer to MAINTENANCE). 8. Valve cannot close against hot inlet. Foreign material may be

between the disc and the valve plug seat. Refer to Replacing

the composition disc for disassembly. Clean.

9. Packing gland assembly is too tight, locking valve stem. Loosen packing gland assembly and lubricate if desired. 10. Bent valve stem; need to replace. Refer to Maintenance for

disassembly instructions.

• Chattering of Valve

1. Regulator installed with the flow of the control medium in reverse of arrow direction on valve body.

2. Pressure differential too high, refer to Water Mixing

Capacities tables for correct pressure differential range. • Constant rise in mixed water temperature

1. A constant rise in temperature may indicate the thermal sys-tem is leaking charge and/or the valve has failed with the port for Hot water fully or partially open.

6. The distance between the marks is the valve plug travel. This should correspond with the TRAVEL value in the VALVE DIMENSIONS table on page 10. No movement or only

par-tial movement indicates the thermal system is defective and should be replaced with a new system.

PREVENTIVE MAINTENANCE

Once every three months, inspect the Regulator as follows: 1. Visually check for leaks from the valve body joints,

piping-to-valve connections, packing and stem areas.

2. Visually check for excessive corrosion on the regulator, includ-ing the bellows, capillary, bulb, thermal system legs, bridge, and yoke. Also check for excessive corrosion on the valve body.

3. Perform the instructions in Testing the Thermal System. Less than full valve travel may indicate a leak in the bellows, capillary, or bulb, or other problems. This may result in exces-sive temperature in the process.

4. Test the temperature adjusting nut assembly for freedom of movement (see Adjust Set Point for instructions).

5. Remove bulb from the process fluid and check for excessive corrosion, or erosion that may weaken the bulb and/or cause thermal system failure.

TROUBLESHOOTING

• Erratic temperature control (valve cycles too hot/too cold) 1. Highly fluctuating supply pressures.

2. Sticking stem caused by packing gland assembly too tight, locking valve stem. Loosen packing gland assembly and lubri-cate if desired.

3. Sticking stem caused by bent valve stem or valve stem not properly lubricated. Refer to Maintenance for replacement. 4. Valve sized incorrectly. Verify valve selection.

5. Regulator is controlling at incorrect set point. Refer to Adjust Set Point.

6. Bulb is poorly positioned and/or oriented, and will not control the actual temperature of the heating/cooling medium. Refer to Install Bulb.

7. Incorrect type of bulb is being used. See Table on page 11.

WARNING: Failure of the thermal system will result

in a constant rise in temperature (or constant high

temperature) of the fluid which you are trying to

control.

Optional Indicating Head

for 1/2" to 2" valves

DIMENSIONS

VALVE DIMENSIONS

Style Valve Size C (in) D (in) E (in) Travel (in) Non Indic. Indicating

Screwed 1/2" 2 1/2 1 3/4 2 7/8 1/8 19 21 Ends 3/4" 2 5/8 2 1/4 3 3/8 3/16 20 22 1" 2 3/4 2 1/2 3 7/8 1/4 21 23 1-1/4" 3 2 3/4 4 1/2 5/16 23 25 1-1/2" 3 1/4 3 5 1/8 5/16 26 28 2" 3 5/8 3 3/8 6 1/8 5/16 31 33 Flanged 2-1/2" 4 1/2 7 1/4 8 1/2 5/8 88 90 Ends 3" 4 7/8 7 1/2 9 1/2 3/4 107 109 4" 5 5/8 9 1/8 11 1/2 1 149 151 Actual Weight (Kg.) Style Valve Size C (mm) D (mm) E (mm) Travel (mm) Non Indic. Indicating

Screwed 1/2" 64 44 73 3 8.6 9.5 Ends 3/4" 67 57 86 5 9.1 10 1" 70 64 98 6 9.5 10.4 1-1/4" 76 70 114 8 10.4 11.3 1-1/2" 83 76 130 8 11.8 12.7 2" 92 86 156 8 14.1 15 Flanged 2-1/2" 114 184 216 16 39.9 40.8 Ends 3" 124 191 241 19 48.5 49.4 4-1/8 [108] 3-5/8" DIA [87]

WELL DIMENSIONS Tank Ftg. Max. Well Pressure - PSI

Bulb Size Well Kit # Well Material F (in) G (in) H (in) J (in) K (in) NPT Shock Non-Shock

1 x 9 709 193 Chrome Plated Copper 15/16 13/16 9 1/16 1 1.11 1" 175 250

808 478 316L Stainless Steel 1 1/16 13/16 8 11/16 1 1/64 1.11 1" 450 675

808 476 Carbon Steel 1 1 13/16 7 11/16 1 1/8 1.125 1" 1000 1500

1 x 20 709 075 Chrome Plated Copper 15/16 13/16 21 1/16 1 1.11 1" 175 250

808 475 316L Stainless Steel 1 1/16 13/16 20 3/8 1 1/64 1.11 1" 450 675

1-1/4 x 24 709 128 Chrome Plated Copper 1 3/16 1 1/16 24 1 1/4 1.25 1-1/4" 150 200

808 461 347 Stainless Steel 1 1/8 1 1/16 23 5/16 1 14/53 1.39 1-1/4" 360 540

Tank Ftg. Max. Well Pressure - kPa

Bulb Size Well Kit # Well Material F (mm) G (mm) H (mm) J (mm) K (mm) NPT Shock Non-Shock

1 x 9 709 193 Chrome Plated Copper 24 21 230 25 28 1" 1207 1724

808 478 316L Stainless Steel 27 21 221 26 28 1" 3103 4654

808 476 Carbon Steel 25 46 195 29 29 1" 6895 10342

1 x 20 709 075 Chrome Plated Copper 24 21 535 25 28 1" 1207 1724

808 475 316L Stainless Steel 27 21 518 26 28 1" 3103 4654

BULB DIMENSIONS Tank Ftg. Max. Pressure - PSI

Bulb Style Size Material A (in) B (in) NPT Shock Non-Shock

D 1 x 9 Copper 15/16 8 1" 175 250

Fixed Union 347 Stainless 15/16 8 1/16 1" 500 725

(& V-Vertical 1 x 20 Copper 15/16 19 7/8 1" 175 250

Fixed Union) 347 Stainless 15/16 19 13/16 1" 500 725

1-1/4 x 24 Copper 1 3/16 22 11/16 1-1/4" 150 200

1-3/8 x 30 Copper 1 3/8 28 5/8 1-1/4" 150 200

J 1 x 9 347 Stainless 15/16 8 3/4 – – –

Plain Bulb* Teflon Coated 15/16 8 3/4 – – –

1 x 20 347 Stainless 15/16 20 1/2 – – –

Teflon Coated 15/16 20 1/2 – – –

JD 1 x 9 347 Stainless 15/16 8 3/4 1" 500 725

Adjustable 1 x 20 347 Stainless 15/16 20 1/2 1" 500 725

G 1 x 9 Copper 2 8 13/16 – – –

Finned Kit* 1 x 20 Copper 2 20 15/16 – – –

Tank Ftg. Max. Pressure - kPa

Bulb Style Size Material A (mm) B (mm) NPT Shock Non-Shock

D 1 x 9 Copper 24 203 1" 4445 6350

Fixed Union 347 Stainless 24 205 1" 12700 18415

(& V-Vertical 1 x 20 Copper 24 505 1" 4445 6350

Fixed Union) 347 Stainless 24 503 1" 12700 18415

1-1/4 x 24 347 Stainless 30 576 1-1/4" 3810 5080

1-3/8 x 30 Copper 35 727 1-1/4" 3810 5080

J 1 x 9 347 Stainless 24 222 – – –

Plain Bulb* Teflon Coated 24 222 – – –

1 x 20 347 Stainless 24 521 – – –

Teflon Coated 24 521 – – –

JD 1 x 9 347 Stainless 24 222 1" 12700 18415

Adjustable 1 x 20 347 Stainless 24 521 1" 12700 18415

G 1 x 9 Copper 51 224 – – –

Finned Kit* 1 x 20 Copper 51 532 – – –

A J A A A B B B B B B B B D Style Bulbs J Style Bulbs JD Style Bulbs

D Style Bulb w/Finned Kit

NPT Pipe Thread NPT Pipe Thread 1" NPT Pipe Thread F G H K

(outer dim. of taper)

2-1/2"-4" WM Assemblies

1/2" - 2" WM Assemblies

PARTS LIST

Valve Body Size

Item Description 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Qty Material

1 Thermal System Refer to Order Code 1 –

1a Locknut Not sold as separate part - refer to Thermal System 1 –

1b Thermal Motor/Bellows Not sold as separate part - refer to Thermal System 2 –

1c Housing Not sold as separate part - refer to Thermal System 1 –

1d Screw Not sold as separate part - refer to Thermal System 2 –

1e Bellows Stop Not sold as separate part - refer to Thermal System 2 –

1f Bulb/Capillary Assembly Not sold as separate part - refer to Thermal System 1 –

2 Piston Plate Retaining Screw 590 816 – 1 SS

3 Piston Plate Washer 590 815 – 1 Zn plate Steel

3 Piston Plate/Shank Assembly – 700 920 1 –

4 Stem Extension 590808B 700128A 1 Brass

5 Spring Adjustment Screw 590 807 – 1 Brass

6 Screw 030546J – 2 Zn plated Steel

6 Bolt – 035123K 2 Zn plated Steel

7 Hex Nut 5/16 x 18 041225K – 2 Cd plated Steel

8 Temp. Adj. Setting Scale 590 813 – 1 Aluminum

– Lower Housing Assembly 590 859 595 515 1 –

9 Yoke/Bridge Assembly 594 515 – 1 –

9A Bridge – 700 125 1 –

9B Yoke – 594517A 1 –

10 Nut, hex 041167J – 1 Zn plated Steel

11 Nut, hex 041 125 041 125 1 Brass

12 Locknut 628 008 – 1 Brass

12 Locknut – 590 405 1 Zn plated Steel

13 Pipe Plug 403 007 403 007 1 Brass

13 Stem Lubricator Kit 590184A 590184A 1 –

14 Packing Gland Assembly 590 763 591 502 1 Brass

15 Packing Kit See Kits on page 14 See Kits on page 14 1 –

15a Packing Spacer " " 1 –

15b Packing Set " " 1 –

15c Packing Spring " " 1 –

15d Packing Washer " " 1 –

15e Packing Ring " " 1 –

16 Temp. Adjusting Rod 590 820 590 820 1 Cd plated Steel

17 1" NPT Tank FItting 705 005 705 005 1 Brass

17 1-1/4" NPT Tank Fitting 705 006 705 006 1 Bronze

18 Spring Guide Washer 590 814 – 1 Steel

18 Spring Seat – 700 804 1 Brass

19 Spring 590 821 590 821 – – – – – 1 Zn plated Steel

19 Spring, inner - - 595 501 595 501 595 501 595 501 – 1 Zn plated Steel

19 Spring, outer - - 595 502 595 502 595 502 595 502 – 1 Zn plated Steel

19 Spring – 121 061 1 Chr. Si. Steel

20 Bonnet Assembly 590 131 590 134 590 137 590 140 590 143 590 146 590 402 1 Brass

21 Gasket – – 084 008 084 016 084 009 084 010 – 2 Silicone

21 Gasket – 632 004 632 005 633 005 1 Gasket Material

22 Stem Head Retainer 601 019 708 036 654 016 654 016 603 012 603 012 590 417 1 416 Stainless

23-24 Disc Assembly 656 311 590 779 590 743 590 690 590 691 590 692 – 1 Brass

23a Disc Holder " " " " " " – 1 Brass

23b Disc Guide " " " " " " – 1 Brass

23c Thrust Collar " " " " " " – 1 Brass

23d Washer " " " " " " – 1 Brass

23e Stem Extension " " " " " " – 1 Brass

23f Disc Sleeve " " " " " " – 1 Brass

24 Disc " " " " " " – 2 Garlock

24 Throttling Disc – 590 431 590 432 590 433 2 Bronze

25 Valve Seat 590 746 590 748 594 513 590 684 594 475 594 459 – 1 Bronze

26 Valve Body Assembly 115 071 115 072 115 073 115 074 115 069 115 070 – 1 Bronze

26 Valve Body & Seat Assembly – 590 428 590 429 590 430 1 Bronze

27 Vlave Flange & Seat Assy. – 590 434 590 435 590 436 1 Brass

28 Cap Screws – 035175K 035175K 035177K 6 Brass

30 Stem Assembly 594813A 594813A 593815A 593815A 594816E 594816E 591843B 591843C 59183D 1 –

For ordering thermal systems, refer to order code, the Powers #11 Product Specification Brochure, or call Powers.

TEMPERATURE RANGES/BULB SIZES

Finned Bulb Kits may be added to style "D" Bulb as noted.

ACCESSORIES

Packing kits can be ordered to replace parts in the packing assembly (See pages 12 & 13).

Bulb SIze Bulb Temp. Range Order Bulb SIze Bulb Temp. Range Order

1/2" to 2" Code High Power Head 2-1/2" to 4" Code

Water Mix Water Mix

1" x 20" 10–60°F (-12–16°C) 01 1-3/8" x 30" 50-80°F 28 55–115°F (12–46°C) 02 70-100°F 22 80–140°F (27–60°C) 03 95-125°F 23 100–160°F (37–71°C) 04 1-1/4" x 24" 120-150°F 24 1" x 9" 110–160°F (43–71°C) 05 140-170°F 25 135–195°F (57–91°C) 07 150-180°F 26 160–220°F (71–104°C) 08 180-210°F 27 200–250°F (93–121°C) 09 230–280°F (110–138°C) 10 260–320°F (127–160°C) 11

Kit # M a t e r i a l Valve Size Stem Size U s a g e P a r t s Lubricant

591 927 Teflon V-ring 1/2" - 2" 1/4" Effective from 200°F-400°F 15A, 15B None Steam: 50 - 200 psi 15C, 15D

15E

594 220 EP V-ring 1/2" - 2" 1/4" Effective from 0°F-300°F 15A, 15B Silicone required Steam: 50 PSI maximum 15C, 15D for installation Water: up to maximum PSI valve rating 15E (optional for service) 594 289 TFE Split Ring 1/2" - 2" 1/4" For replacement only 15B, 15D Silicone

Effective from 40°F-366°F Part #087 126

591 928 Teflon V-ring 2-1/2" - 4" 3/8" Effective from 200°F-400°F 15A, 15B None Steam: 50 - 200 psi 15C, 15D

15E

594 221 EP V-ring 2-1/2" - 4" 3/8" Effective from 0°F-300°F 15A, 15B Silicone required Steam: 50 PSI maximum 15C, 15D for installation Water: up to maximum PSI valve rating 15E (optional for service) 594 290 TFE Split Ring 2-1/2" - 4" 3/8" For replacement only 15B, 15D Silicone

Effective from 40°F-366°F Part #087 126

Kit # Bulb Dims. Width (in) Length (in) Description

701 549 1 x 9 2 8 13/16 G Style Finned Kit (Copper)

ORDER CODE

Valves Type

WM

3-Way Water Mix

Valve Sizes

1/2" (15mm)

050

3/4" (20mm)

075

1" (25mm)

100

1-1/4" (32mm)

125

1-1/2" (40mm)

150

2" (50mm)

200

Applications

Mixing

M

Bulb/Capillary Material & Length

Copper 8'

C08

Copper 15'

C15

Copper 30'

C30

Stainless Steel 8'

S08

Stainless Steel 15'

S15

Stainelss Steel 30'

S30

Bulb Size

Fixed Union

D

No Pipe Fittings (N/A Copper)

J

Adj. Union (N/A in H head)

A

Fixed Union (D Type) Vertical

V

Head Assembly

Non-indicating

N

Indicating

I

Range/Bulb Size

See chart on page 14

##

Select Range with Set Point in

UPPER THIRD for best performance.

595-Valve Assembly

Thermal System Assembly

USA: Phone: 1.800.669.5430 • Fax 1. 847. 229 . 0526 • www.powerscontrols.com Canada: Phone: 1.888.208.8927 • Fax 1. 888. 479.2887 • www.powerscontrols.ca

The Seller warrants that the equipment manufactured by it and covered by this order or contract is free from defects in material and workmanship and, without charge, equipment found to be defective in material or workmanship will be repaired, or at Seller’s option replaced F.O.B. original point of shipment, if written notice of failure is received by Seller within one (1) year after date of shipment (unless specifically noted elsewhere), provided said equipment has been properly installed, operated in accordance with the Seller’s instructions, and provided such defects are not due to abuse or decomposition by chemical or galvanic action. THIS EXPRESS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, GUARANTEES, OR REPRESENTATIONS, EXPRESS OF IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. The Seller assumes no responsibility for repairs made on the Seller’s equipment unless done by the Seller’s authorized personnel, or by written authority from the Seller. The Seller makes no guarantee with respect to material not manufactured by it.